BR102014030174A2 - elastic averaged alignment system and method of manufacturing an elastic averaged alignment system - Google Patents

Abstract

Abstract "Elastic averaged alignment system, and method of manufacturing an elastic averaged alignment system" in one aspect, an elastic averaged alignment system is provided. the system includes a first component having an inner surface and an alignment element extending therefrom, and a second component including a support having an internal wall at least partially defining an alignment hole configured to receive the alignment element for mating the first component and the second component. The bracket is configured to engage and support the inner surface of the first component when the first and second components are coupled. The alignment element is an elastically deformable material such that when the alignment element is inserted into the alignment hole, the alignment element elastically deforms to a final averaged configuration to facilitate alignment of the first component and the second. component in a desired orientation.

Description

'‘ELASTIC MEDIA CALCULATED ALIGNMENT SYSTEM, L. METHOD OF MANUFACTURING A LM MEDIA ELASTIC CALCULATED ALIGNMENT SYSTEM FIELD OF THE INVENTION

The present invention relates to non-adaptable components and, more specifically, to elastic medium components for alignment between them.

BACKGROUND

Components, in particular vehicle components that are to be coupled together in a manufacturing process, may be mutually positioned relative to one another by alignment characteristics which are oversized holes and / or undersized vertical shoulders. Such alignment characteristics are typically sized to provide spacing to freely move the components together to align them without creating interference between them, which would impair the manufacturing process. Such an example includes two-way and / or four-way male alignment features; typically vertical shoulders, which are received in corresponding female alignment characteristics, typically holes in the form of slits or holes. The components are formed with a predetermined clearance between the male alignment characteristics and their respective female alignment characteristics to match the expected size and positional variation tolerances of the male and female alignment characteristics that result from production (or manufacturing) variations.

As a result, significant positional variation can occur between two coupled components having the aforementioned alignment characteristics, which may contribute to the presence of undesirably large variation in their alignment, particularly with respect to interstices and spacing between them. In the event that misaligned components are also part of another assembly, such misalignment may also affect the function and / or aesthetic appearance of the entire assembly. Regardless of whether such misalignment is limited to two components or an entire set, it can negatively affect function and result in poor perception. In addition, slack between misaligned components can lead to relative movement between them, which can cause unwanted noise, such as creaking and crackling, and result in poor quality perception.

SUMMARY

In one aspect, an elastic averaged alignment system is provided. The system includes a first component having an inner surface and an alignment member extending therefrom, and a second component including a support having an inner wall at least partially defining an alignment hole configured to receive the alignment element for coupling. the first component and the second component. The bracket is configured to engage and support the inner surface of the first component when the first and second components are coupled. Alignment deformation is a highly deformable material such that when the alignment element is inserted into the alignment hole, the alignment element deforms elastically to a final averaged configuration to facilitate alignment of the first component and the second. component in a desired orientation.

In another aspect, a vehicle is provided. The vehicle includes a chassis and an elastic averaged alignment system that is fully arranged with the chassis. The elastic averaged alignment system includes a first component having an inner surface and an alignment element extending therefrom, and a second component including a support having an inner wall at least partially defining an alignment hole configured to receive the alignment element to couple the first component and the second component. The bracket is configured to engage and support the inner surface of the first component when the first and second components are coupled. The alignment element is an eiastically deformable material such that when the alignment element is inserted into the alignment hole, the alignment element deforms eiastically to a finely averaged configuration to facilitate alignment of the first component and the second. component in a desired orientation.

[006] In yet another aspect, a method of manufacturing an elastic averaged alignment system is provided. The method includes forming a first component having an inner surface and an alignment member extending therefrom, and forming a second component having a support including an inner wall defining at least partially an alignment hole configured to receive the member. alignment to couple the first component and the second component. The bracket is configured to engage and support the inner surface of the first component when the first and second components are coupled. The method further includes shaping the alignment element from an eiastically deformable material such that when the alignment element is inserted into the alignment hole, the alignment element deforms eiastically to a final configuration averaged elastic to facilitate alignment of the first component and the second component in a desired orientation.

The above features and advantages and other features and advantages of the invention are immediately apparent from the following detailed description of the invention when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

Other features, advantages and details are given, by way of example only, in the following detailed description of embodiments, the detailed description with reference to the drawings, in which: [009] Figure 1 is a perspective view of a system of Example Alignment Calculated in Tensile Mean: Figure 26 is a cross-sectional view of a portion of the system shown in Figure 1 and prior to assembly;

Figure 3 is a cross-sectional view of a portion of the system shown in Figure 1 and after mounting;

[001.2] Figure 4 is a cross-sectional view of an alternate embodiment of a portion of the system shown in Figure 1 and prior to assembly; and Figure 5 is a side view of a vehicle that can use any of the calculated averaged alignment systems shown in Figures 1-4.

DETAILED DESCRIPTION

The following description is purely illustrative in nature and is not intended to limit the present description, its application or uses. For example, the embodiments shown are applicable to vehicle chassis panels, but the alignment system set forth herein may be used with any suitable components to provide elastic means for the accurate positioning and alignment of all coupling components and fitting applications. components, including many industrial, consumer products (e.g., consumer electronics, various appliances and the like), transportation, power and aerospace applications, and particularly including many other types of vehicle components and applications, such as various interiors, exterior and under-bonnet components and vehicle applications. It must be understood that. Throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and characteristics.

When used herein, the term "highly deformable" refers to components, or portions of components, including component characteristics, comprising materials having a generally elastic deformation characteristic, wherein the material is configured to undergo resilient changes. slightly reversible in shape, size, or both in response to the application of a force. The force causing resiliently reversible or elastic deformation of the material may include a tensile, compressive, shear, bending or twisting force, or various combinations of these forces. Elastably deformable materials may exhibit linear elastic deformation, for example that described in accordance with Hooke's law, or nonlinear elastic deformation. [0016] Elastic average provides the elastic deformation of the interface (s) between coupled components, where the mean strain provides precise alignment, the manufacturing position variation being minimized for Xniin, defined by Xmin = ΧΛ / Ν, where X is the manufacturing position variation of the coupling component positioning characteristics and N is the number of characteristics entered. For elastic averaging, a highly deformable component is configured to read at least one characteristic and its contact surface (s) that are overrestrictive and provide an interference fit with a coupling characteristic of other component and its contact surface (s). The over-constrained condition and interference fit resiliently, reversibly (elastially) deforms at least one of at least one or the coupling characteristic, or both characteristics. The resiliently reversible nature of these component characteristics enables repeatable insertion and removal of components, which facilitates assembly and disassembly. In some embodiments, the highly deformable component configured to have at least one feature and associated coupling feature set forth herein may require more than one of such features, depending on the requirements of a particular embodiment. Positional variation of components may result in varying forces being applied over regions of contact surfaces that are overrun and engaged during component insertion in an interference condition. It should be appreciated that a single inserted component may have the elastic mean calculated with respect to a component perimeter length. The principles of elastic average are described in detail in commonly assigned US Patent Application No. 13 / 187,675, published as Puh. No. 2013/0019455, the disclosure of which is incorporated by reference herein in its entirety. The above embodiments provide the ability to convert an existing component that is not compatible with the elastic averaging principles described above, or would be further aided by the inclusion of a four-way elastic average system. as shown herein, for an assembly that facilitates elastic averaging and the benefits associated therewith.

Any suitable elastably deformable material may be used for the coupling components and alignment characteristics set forth herein and discussed in more detail below, particularly those materials which are highly deformable when formed into the characteristics described herein. This includes various metals, polymers, ceramics, inorganic materials or glasses, or composites of any of the above materials, or any other combinations thereof, suitable for the purpose set forth herein. Many composite materials are contemplated, including various charged polymers, including glass, ceramic, metal and inorganic charged polymers, particularly glass, metal, ceramic charged polymers. inorganic or carbon fiber. Any suitable charge morphology may be employed, including all particle or fiber shapes and sizes. More particularly, any suitable type of fiber may be used, including continuous and discontinuous pounds, nonwoven fabrics and cloths, felts or tow, or a combination thereof. Any suitable metal may be used, including various grades and alloys of steel, cast iron, aluminum, magnesium or titanium, or composites thereof, or any other combinations thereof. Polymers may include both thermoplastic polymers and thermostable polymers, or composites thereof, or any other combinations thereof, including a wide variety of polymer and polymer mixtures. In one embodiment, a preferred plastics material is one having elastic properties such that it deforms elastically without fracture, such as a material comprising an acrylonitrile butadiene styrene (ABS) polymer, and more particularly a polycarbonate polymer blend. ABS (PC / ABS). The material may be in any shape and shaped or manufactured by any suitable process, including stamped or shaped metal, composite plates or other plates, forgings, extruded parts, pressed parts, hollow parts, or shaped parts and the like, to include features. deformable materials described here. Alignment characteristics, elastically deformable, and associated component may be formed in any appropriate manner. For example, the elastically deformable alignment characteristics and the associated component may be integrally formed, or they may be formed entirely separately, and subsequently affixed together. When fully formed, they can be formed as a single part by a plastic injection molding machine, for example. When formed separately, they may be formed of different materials to provide a predetermined elastic response characteristic, for example. The material or materials may be selected to provide a predetermined elastic response characteristic of any or all of the alignment characteristics. deformable, the associated component or the coupling component. The predetermined elastic response characteristic may include, for example, a predetermined modulus of elasticity.

[0018] When used herein, the term vehicle is not limited to an automobile, truck, van or sport utility vehicle only, but includes any self-propelled, towed, or mobile means of transport suitable for transporting or supporting a load.

Figure 1 illustrates an example, averaged elastic alignment system 10, which generally includes a first component 100 to be coupled to a second component 200. Figure 2 illustrates a portion of the first component 100 and the second component 200 prior to assembly, and Figure 3 illustrates a portion of first component 100 and second component 200 after assembly.

In the exemplary embodiment, the first component 100 includes an elastically deformable alignment member 102, and the second component 200 includes an inner wall 202 at least partially defining an alignment hole 204. The second component 200 also includes a support 206 having an inner wall 208 at least partially defining the alignment hole 204. The alignment element 102, the alignment hole 204, and support 206 are fixedly disposed on or integrally formed with their respective member 100, 200 for the proper alignment and orientation when components 100 and 200 are coupled. While various alignment elements 102, alignment holes 204, and brackets 206 are illustrated, components 100 and 200 may have any number and combination of corresponding alignment elements 102, alignment holes 204, and brackets 206. The alignment element is elastably 102 is configured and arranged to engage in an interfering, deformable, and mating engagement with alignment hole 204, as discussed in more detail herein, to precisely align first component 100 with second component 200 in two or four directions, such as the +/- x direction and + / ~ y direction of an orthogonal coordinate system, for example, which is referred to herein as two-way and four-way alignment. In addition, the elastably collapsible alignment member 102 mates with alignment hole 204 to facilitate a hard and rigid connection between first component 100 and second component 200, thereby reducing or preventing relative movement therebetween.

In the exemplary embodiment, first component 100 generally includes an outer face 104 and an inner face 106 from which the alignment member 102 extends. The alignment member 102 is a generally circular hollow tube having a central axis 108, a proximal end 110 coupled to the inner face 106, and a distal end 112. However, the alignment member 102 may have any cross-sectional shape that allows the system 10 functions as described herein. In the exemplary embodiment, the first component 100 is made from a highly deformable material such as plastic. However, the first component 300 may be made from any suitable material that enables system 10 to function as described herein.

The second component 200 generally includes an outer face 210 and an inner face 212. In the exemplary embodiment, the alignment hole 204 is illustrated as having a generally circular cross section. Alternatively, the alignment hole 204 may have any shape that allows system 10 to function as described herein. For example, alignment hole 204 may be an elongated slot (for example, similar to the shape of the elastic tube alignment system. Described in copending US Patent Application No. 13 / 187,675 and particularly illustrated in Figure 13 thereof), as shown in figure 4 as a slot 204b. In the exemplary embodiment, the second component 200 is made from a rigid material such as plastic. However, the second component 200 may be fabricated from any suitable material which enables system 10 to function as described herein. The holder 206 is a generally circular hollow tube having a central axis 214, a proximal end 216 coupled to the face. 212, and a distal end 218. However, bracket 206 may have any cross-sectional shape that allows system 10 to function as described herein. For example, as shown in FIG. 1, a bracket 206a may have a cross-sectional shape similar to a large circular crown, or the bracket may have a cross-sectional shape similar to the slotted alignment hole 204b shown in FIG. 4. Additionally, the support may be formed by a plurality of tabs or segments generally forming a desired cross section, as shown in Figure 4 as the support 206b. The inner support wall 208 is oriented at an angle to the central axis 214, and the side wall 208 may be angled by a distance "L" over only a portion of the entire height "h" of support 206 (FIGS. 2). -3) or can be angled along the entire height 'ΤΓ of bracket 206 (not shown).

In addition, the angle "u" and the length "L" may be variously designed to adjust the amount of force required to insert the alignment member 102 into the alignment hole 204. For example, when the angle " a "is increased, the force required for insertion of the alignment element is decreased, and vice versa. When the length" L "is increased, bracket 206 provides a longer entry for the alignment element 102, which facilitates Reduction of the amount of force required for insertion of the alignment element In addition, a longer length “L” and / or greater angle “a” increases the relative area for insertion of the alignment element, thus facilitating a lower degree of precision in initial alignment of mounting components 100 and 200. As such, the inner support wall 208 helps guide the alignment member 102 to its final position within the alignment hole 204.

Further, the inner wall 202 and / or the support 206 may be resiliently resilient to facilitate added elastic average tuning of the system 10. For example, the inner wall 202 and / or a surrounding portion of the second component 200 may be made from an elastically deformable material and / or having a smaller thickness or gauge than the rest of component 200. As such, during insertion of the alignment member 102 into the alignment hole 204, the inner wall 202 and / or a portion surrounding component 200 deforms elastically to a final configuration averaged over elastic to facilitate alignment of first component 100 and second component 200 in a desired orientation. Accordingly, the first component tube thickness, the support tube thickness, and the material or gauge of the second component can be adjusted to tune the average elastic coupling between first component 100 and second component 200.

Although not limited to any particular structure, the first component 100 may be a decorative trim component of a vehicle with the customer visible side being the outer face 104, and the second component 200 may be a supporting substructure which it is part of, or affixed to, the vehicle and upon which the first component 100 is fixedly mounted in precise alignment.

To provide an arrangement, in which the elastically deformable alignment member 102 is configured and arranged to interfere, deformably and in conjunction with the inner wall 202 of the alignment hole 204, the diameter of at least one portion of the bore hole. Alignment 204 is smaller than the diameter of the alignment member 102, which necessarily creates an interference fit between the elastically deformable alignment member 102 and alignment hole 204. In addition, the support inner wall 208 forms a bevel to facilitate insertion of the alignment member 102. As such, when inserted into the alignment hole 204, portions of the elastically deformable alignment member 102, elastically deform to a final calculated average elastic configuration, which aligns the alignment member 102 with the alignment hole. alignment 204 in four flat orthogonal directions (the direction d and +/- x and the +/- y direction When the alignment hole is a slot, the alignment element is aligned in two flat orthogonal directions (the -t - / - x direction or the +/- Μι 0028 direction) In the exemplary embodiment, the support 206 is oriented at the edge of the inner wall 202 and provides a support platform at a height "h" below the second component inner face 212. The first component inner face 106 rests on an end face support 220 when the elastically deformable alignment member 102 is configured and arranged to interfere, deformably and in conjunction with the alignment hole 204. Alternatively mentioned, the holders 206 are arranged and configured to provide a final relative position between the hole of alignment 204 and the elastically deformable alignment member 102, at an elevation "h" above the inner face 212.

Figure 4 illustrates another exemplary embodiment of the second component 200. In the exemplary embodiment, component 200 includes a slotted hole 204b, defined by an inner wall 202b, and two opposing supports 206b having angled inner wall 208b. .

Although Figure 1 represents three elastically deformable alignment members 102 in a corresponding hole 204 to provide four-way alignment of the first component 100 with respect to the second component 200, it will be appreciated that the scope of the invention is not limited to this. and encompasses other amounts of elastically deformable alignment element types used in conjunction with elastically deformable alignment element 102 and corresponding orifice 204.

In view of the foregoing, and with reference now to Figure 5, it will be appreciated that an exemplary embodiment of the invention includes the elastic average alignment system 10 implemented in a vehicle 40 having a chassis 42 with a linear alignment system. 10, as shown herein, integrally arranged with chassis 42. In the embodiment of Figure 5, the elastic mean alignment system 10 is shown forming at least a portion of a vehicle front grille 40. However, it is contemplated that a elastic medium alignment system 10, as set forth herein, may be used with other vehicle features or components, such as, for example, external chassis trim, interior trim, inserts, moldings, and decorative trim.

An exemplary method of manufacturing the elastic averaged alignment system 10 includes forming the first component 100 with a minus one alignment element 102. The second component 200 is formed with inner wall 202 and support 206, which includes inner wall 208 at least partially defining alignment hole 204 with inner wall 202. However, the second component 200 may optionally exclude inner wall 202. The inlet on bracket 206 may be formed to the desired length “L'1 and the wall 208 is formed at the desired angle "a". At least one of the alignment member 102, bracket 206, and inner wall 208 is formed to be elastically deformable such that when alignment member 102 is inserted into the bore hole. Alignment 204, at least one of the alignment member 102, the bracket 206, and the inner wall 208 elastically deform to a final average calculated configuration. elastic day to facilitate alignment of the first component 100 and the second component 200 in a desired orientation, Systems of combined averaged mounting methods are described herein. Systems generally include a first component with an elastically deformable alignment member positioned for insertion into a second component alignment hole. The alignment hole is at least partially defined by a bracket formed on the second component. The bracket includes angled inner walls to facilitate reception of the alignment member in the alignment hole. The length of the bracket and the angle of the inner walls are variable to controlling the amount of force required to insert the alignment element into the alignment hole. The coupling of the first and second components has the elastic mean calculated on a corresponding pair or pairs of elastically deformable alignment elements and alignment holes to precisely couple the components in a desired orientation. As such, the systems and methods provide an easily assembled system that can be adapted to the desired applications, reduces or eliminates the need for fasteners to couple components, and provides an excellent viewing surface.

Although the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or particular material to the teachings of the invention without departing from its essential scope. Accordingly, it is intended that the invention not be limited to the foregoing embodiments, but that the invention will include all embodiments falling within the scope of the application.

KING I saw ND1C ACTIONS

Claims (10)

Elastic averaged alignment system, characterized in that it comprises: a first component comprising an inner surface and an alignment element extending therefrom; and a second component comprising a support having an inner wall at least partially defining an alignment hole configured to receive the alignment element for coupling the first component and the second component, the support configured to engage and support the first component internal surface when the first and second components are coupled; wherein the alignment element is an eiastically deformable material such that when the alignment element is inserted into the alignment hole, the alignment element deformed to an elastic average calculated final configuration to facilitate alignment of the first component and of the second component in a desired orientation. System according to Claim 1, characterized in that the support is tubular. System according to claim 1, characterized in that the second component further comprises a second inner wall further defining the alignment hole; System according to Claim 1, characterized in that the first component comprises more than one of the eiastically deformable alignment element and the second component comprises more than one of the support and alignment hole, more than one of the elements. deforming alignment elements being geometrically distributed with respect to respective of more than one of the alignment supports and holes, such that portions of the deforming alignment element of the respective of more than one of the deforming alignment elements when engaged with respective of the more than one of the brackets and alignment holes deform elastically to a resilient averaged final configuration which further aligns the first component with the second component in at least two of the four planar orthogonal directions. System according to claim 1, characterized in that at least a portion of the inner support wall defines a chamfer. A method of manufacturing an elastic averaged alignment system, the method characterized in that it comprises forming a first component having an inner surface and an alignment element extending therefrom; forming a second component having a support including an inner wall defining at least partially an alignment hole configured to receive the alignment element for coupling the first component and the second component, the support configured to engage and support the internal surface of the first component. when the first and second components are coupled; and shaping the alignment member from an elastically deformable material such that when the alignment member is inserted into the alignment hole, the alignment member elastically deforms to a final averaged configuration to facilitate alignment of the first component and the second component in a desired orientation. Method according to claim 6, characterized in that it further comprises shaping the support as tubular. A method according to claim 6, characterized in that it further comprises forming a second inner wall into the second component, the second inner wall further defining the alignment hole. A method according to claim 6, wherein said forming a first component comprises forming a first component with an inner surface and a plurality of alignment elements extending therefrom, and wherein said forming a second component comprises forming a second component having a plurality of supports including an inner wall at least partially defining an alignment hole, A method according to claim 9, characterized in that it further comprises shaping the first and second components such that the plurality of alignment elements are geometrically distributed with respect to respective plurality of supports and respective alignment hole; such that portions of the respective elastically deformable alignment element of the plurality of elastically deformable alignment elements, when engaged with respective plurality of brackets and alignment holes, deform elastically to a final calculated average elastic configuration that still aligns the first one. component with the second component in at least two of the four flat orthogonal directions.